Apparatus, system, and method for indicating a position of valve of wellsite equipment

ABSTRACT

Embodiments of the present disclosure relate to an apparatus, a system, and a method for detecting and indicating the operational position of a valve of wellsite equipment. The apparatus comprises a mount portion and a housing portion. The mount is operatively coupled to a non-moving part of the valve and the housing portion is configured to receive a sensor therewithin. The sensor is configured to detect the position of a moving part of the valve and to provide an output signal indicative of the position of the moving part of the valve. The position of the moving part of the valve is indicative of the operational position of the valve. The system comprises one or more such apparatus for detecting and indicating the operational position of one or more valves on a wellsite or well pad.

TECHNICAL FIELD

This disclosure generally relates to wellsite equipment. In particular,the disclosure relates to an apparatus, system, and method for detectingand indicating a position of a valve of wellsite equipment.

BACKGROUND

The oil and gas industry is increasingly incorporating digitalization toassist in production monitoring and decision making at a wellsite and ona well pad. When hydrocarbon recovery includes hydraulic fracturing, orotherwise, one of the key pieces of information at the wellsite is toknow the operational position of the valves on the frac tree and/orzipper manifold and/or other wellsite equipment. It is critical to knowwhether a valve is open, closed, or in a position in between. Currently,service operators send an individual to visually check the position of avalve actuator. This may require the individual to enter or pass throughone or more hazardous areas of the well pad. In other instances, serviceoperators may use some form of reporting technology for obtaining valveposition information that is typically either mounted to the frac-headvalve itself or permanently installed on a specialized accumulator.

One drawback of mounting equipment on the frac tree is that thedifferences in valves, including from different vendors or suppliers,necessitates different mounting hardware for different valves, which canbe inefficient, of large physical dimensions and costly forinstallation. For example, this can be accomplished by machining andmodifying each valve for a position detection assembly to be mounted on,which is costly and inefficient as many valves need to be modified inorder to have enough in circulation to supply for jobs. Another exampleis installing a temporary solution, however the types that have beendeveloped are exceedingly long due to their shaft contact design forproviding contact-based positon detection.

A drawback of permanently installed valve-position equipment, as anintegral part of a specialized accumulator or otherwise, is that theinformation acquired from this equipment may not be readily shared byvendors or suppliers with other services requiring it. Not having orsharing all of the data negates, to a certain degree, the usefulness ofthe valve position information because different service operators on awellsite may require the valve position information at a given time, butonly some may be able to access it. Furthermore, such specializedequipment is costly; particularly, when one considers that thespecialized unit would likely replace an existing, non-specialized unitthat performs the same functions properly.

Therefore, a need exists for an improved way to obtain valve positioninformation at the wellsite or well pad.

SUMMARY

The embodiments of the present disclosure relate to an apparatus,system, and method for indicating a position of a valve of wellsiteequipment.

Some embodiments of the present disclosure provide an apparatus fordetecting and indicating a position of a valve of wellsite equipment.The apparatus comprising a sensor that is configured to detect theposition of a moving part of a valve and to provide an output signalindicative of the position of the moving part.

A system for detecting and indicating an operational position of avalve, the system comprising: an apparatus and a processor. Theapparatus comprising a first end that configured to operably couple to avalve or associated equipment and a second end and a sensor. The sensorhoused between the first end and the second end, the sensor configuredto be in communication with a target surface for contactless detectingof the operational position of the valve based upon the detecteddistance between the sensor and the target surface and the sensorfurther configured to indicate the operational position by communicatingan output signal. The processor is configured to receive the outputsignal and to generate a display signal that indicates the operationalposition of the valve.

An apparatus for detecting and indicating an operational position of avalve. The apparatus comprises: a first end that configured to operablycouple to a valve or associated equipment and a second end. Theapparatus also comprises a sensor housed between the first end and thesecond end, the sensor configured to be in communication with a targetsurface for contactless detecting of the operational position of thevalve based upon the detected distance between the sensor and the targetsurface.

Some embodiments of the present disclosure relate to a method A methodfor detecting and indicating an operational position of a valve, themethod comprising: securing an apparatus to a valve or associatedequipment, the apparatus comprising a sensor, detecting the distancebetween the sensor and a target surface of the valve or associatedequipment; and indicating the operational position of the valve actuatorbased on the detected distance.

Without being bound by any particular theory, the embodiments of thepresent disclosure provide an apparatus, system, and method thatgenerate information about the position of a valve. Knowing the positionof the valve provides information about flow of fluids towards, throughor away from an accumulator of a wellsite or well pad hydraulic system,a frac flow control unit, a frac zipper-manifold, a frac tree, a wellChristmas tree, a blowout preventer, or therebetween. Such informationabout fluid flow may help avoid accidents at the wellsite and/or wellpad. Examples of such accidents can include when a wellhead valve isopened or closed at the incorrect time during a well operation, such asa hydraulic fracking operation or a wireline operation. Furthermore,some embodiments of the present disclosure permit aggregating,displaying and sharing of valve position information between differentindividuals working on the same wellsite and multiple wellsites of agiven well pad and individuals who are overseeing operations of multiplewellsites from a remote location. Furthermore, the embodiments of thepresent disclosure can be added on to existing wellsite equipmentwithout great effort, which facilitates the sharing of valve positioninformation across individuals with access to different computer systemsand different information technology infrastructures. In effect, theembodiments of the present disclosure are agnostic to the types, sizes,dimensions and configuration of valves present at the wellsite and tothe specific computer and data systems that individuals may already beusing in relation to wellsite operations.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become moreapparent in the following detailed description in which reference ismade to the appended drawings.

FIG. 1 shows an apparatus, according to embodiments of the presentdisclosure, for use with a wellhead valve, wherein FIG. 1A is a top-planview; FIG. 1B is a cross-sectional view taken through line A-A in FIG.1A; FIG. 1C is a cross-sectional view taken through line A-A in FIG. 1A;FIG. 1D is a cross-sectional view taken through line A-A in FIG. 1A; andFIG. 1E is a cross-sectional view taken through line A-A in FIG. 1A.

FIG. 2 shows further embodiments of the apparatus, wherein FIG. 2A showsa mid-line cross-sectional view of the apparatus in use with a wellheadvalve; and, FIG. 2B shows a top-plan view of the apparatus in use with arotationally actuated wellhead valve.

FIG. 3 shows an apparatus, according to embodiments of the presentdisclosure, wherein FIG. 3A is an isometric view of the apparatus; FIG.3B is an isometric view of a mount portion of the apparatus; and, FIG.3C is an isometric view of a housing portion of the apparatus.

FIG. 4 shows further views of the apparatus of FIG. 3 , wherein FIG. 4Ais a top-plan view of the apparatus; and FIG. 4B is a cross-sectionalview taken through the line A-A in FIG. 4A.

FIG. 5 shows another embodiment of an apparatus, according to thepresent disclosure, wherein FIG. 5A is a top-plan view of the apparatus;and, FIG. 5B is a cross-sectional view taken through the line A-A inFIG. 5A.

FIG. 6 shows schematic of a system, according to embodiments of thepresent disclosure.

FIG. 7 shows schematic of another system, according to embodiments ofthe present disclosure.

FIG. 8 shows a logic flow diagram of a method, according to embodimentsof the present disclosure, wherein FIG. 8A show the logic of a methodbased on the operational position of a valve being in a desiredposition; FIG. 8B shows the logic of a method based on the operationalposition of a valve being in an undesirable position; and FIG. 8C showsthe logic of a method to remotely actuate a valve to an intermediateposition.

FIG. 9 shows a logic flow diagram of a method, according to embodimentsof the present disclosure.

FIG. 10 shows steps of a method for detecting and indicating theoperational position of a valve.

DETAILED DESCRIPTION

The embodiments of the present disclosure relate to an apparatus,system, and method for detecting and indicating an operational positionof a valve of that controls the flow of fluids to, through or away fromwellsite equipment. As used herein, the expression “wellsite equipment”refers to a component of or a piece of equipment that can be used or isused at a wellsite. The valve can occupy various operational positionsthat regulate the flow of fluids through the valve so as to influencethe operation of the wellsite equipment or so as to control the flow offluids upstream or downstream of the wellsite equipment. For example,the valve can be, but is not limited to: a swab valve, a pump-downvalve, a crown valve, an isolation valve, a hydraulic master-valve, oneor more side port valves, one or more zipper manifold valves, aflow-back valve, a pump-down valve and any other valve that contributesto the functionality of wellsite equipment. Regardless of its positionand function on the wellsite, the valve may be a butterfly valve, a plugvalve, a ball valve, a low-torque valve, a low-torque plug valve, a gatevalve, a wedge gate valve, a disc and stem valve or any other type ofvalve that can be actuated by an actuator.

A number of different control mechanisms regulate the flow of fluids to,through and from the well. For example, moving parts of valves withinwellsite equipment can change operational position, by opening andclosing, to control the flow of fluids to and from the well. Forexample, a number of valves may be positioned through different sectionsof a surface-borne, hydraulic fracturing system or other systems relateto services being performed on the well. The operational position ofeach valve is controlled by a valve actuator. Valve actuators cancontrol the operational position of a valve through one or more ofmanual, hydraulic, pneumatic or electronically actuated controlmechanisms. Some valve actuators may provide direct control of a valveand some valve actuators may be positioned remotely from the valve forindirect control of the operational position of a valve.

Some embodiments of the present disclosure relate to an apparatus,system and method for detecting and indicating the position of a valveof wellsite equipment. For the purposes of this disclosure, the term“detecting” and similar terms, refer to capturing positional informationof a movable part of the valve, relative to a fixed point. Theembodiments of the present disclosure relate to detecting the distancebetween a non-moving sensor and a target surface of a moving part of thevalve without directly contacting the moving part of the valve (i.e.non-contact detection). As will be appreciated by those skilled in theart, the sensor may also be operatively coupled to the moving part ofthe valve and the target surface may be a surface of a non-moving partof the valve, a surface of the wellsite equipment, a surface of theapparatus described herein or combinations thereof. Furthermore, theembodiments of the present disclosure allow for detecting the positionof a moving part of a valve throughout the entire range of intendedmotion and beyond. This allows a user to know the location of the movingpart of the valve within its intended range of movement (e.g. 25%towards a closed position, 25% towards an open position, 50% from closedand open positions). If the moving part of the valve is detected to beoutside of its intended range of movement, that may indicatedmaintenance or repair of the valve is required and/or that the apparatusmay require an adjustment, recoupling or replacement. Detecting theposition of a moving part of the valve can be a direct or indirectmeasure of the operational position of the valve. For the purposes ofthis disclosure, the term “indicating” and similar terms, refer toconveying the detected position of the moveable valve part.

Some embodiments of the present disclosure relate to an apparatus thatis operatively coupleable to a non-moveable part of a valve or associatewellsite equipment. The apparatus includes a sensor for detecting theposition of a moving part of the valve wherein the moving part of thevalve operates to, directly or indirectly, change the operationalposition of the valve. The sensor is also configured for generating anoutput signal that indicates the position of the moving part of thevalve and, therefore, the operational position of the valve. When theapparatus is operatively coupled to the non-moving part of the valve,the apparatus may detect and indicate whether the valve is in a firstposition, a second position, or an intermediate position therebetween.The apparatus may also detect and indicate whether the valve has movedto a position beyond its intended range of movement, which may indicatedmaintenance, repair or replacement of the valve is required and/or thatthe apparatus requires an adjustment, recoupling or replacement. Movingthe valve between these operational positions will permit, restrict, orstop at least a portion of fluids from flowing to, through or from thevalve.

Some embodiments of the present disclosure relate to a system fordetecting and indicating the position of a valve that forms part ofwellsite equipment. The system comprises an apparatus with a sensor anda processor. The apparatus is operatively coupleable to a non-movingpart of the valve and the sensor is configured to receive to detect andindicate the position of a moving part of the valve. The sensor is alsoconfigured to generate and communicate an output signal indicative ofthe operational position of the valve. The processor is operativelycoupled to the at least one sensor and the processor is configured toreceive and process an output signal from the sensor. The processor isfurther configured to generate the processed output signal as a displaysignal. In some embodiments of the present disclosure, the systemfurther comprises a remote display unit for receiving the display signaland for generating a display that is indicative of the position of thevalve. In some embodiments of the present disclosure, the remote displayunit may form part of a Human-Machine-Interface (HMI) and/or the remotedisplay unit may be part of an individual computer display. In someembodiments of the present disclosure, the system includes multipleapparatus that each provide their respective output signals to a singleprocessor (or to multiple processors in communication with each other)so that the remote display unit can receive display signals thatindicate the operational position of multiple valves at a wellsite or awell pad at a given time.

Some embodiments of the present disclosure relate to a method ofdetecting and indicating a position of a valve that forms part ofwellsite equipment. The method comprises the steps of coupling anapparatus to a non-moving part of a valve, detecting the operationalposition of the valve by detecting the position of a moving part of thevalve and observing an output signal generated by the sensor.

As discussed elsewhere herein, several issues and/or inefficienciesexist with conventional technologies for indicating the position of avalve at a wellsite. For example, knowing the operational position of avalve that controls the flow of fluids towards, through or from a pieceof wellsite equipment may be beneficial to the safe and efficientwellsite operations by letting one or more operators know theoperational position of the valve, so as to know the operational stateof the wellsite equipment.

The technology of the present disclosure is suitable for severalapplications and use with different types of wellsite equipment. Withreference below to the drawings herein, the present disclosure discussesthe technology in the context of indicating the operational position ofa valve and the skilled person will appreciate that various applicationsand wellsite equipment uses are applicable. For example, the embodimentsof the present disclosure can be used for detecting and indicating theoperational position of a valve of at least the following wellsiteequipment: a frac flow control unit, a frac zipper-manifold, a fractree, a wellhead Christmas tree, a blowout preventer, or any valvetherebetween.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this disclosure belongs. Exemplary terms are definedbelow for ease in understanding the subject matter of the presentdisclosure.

As used herein, the term “about”, when referring to a measurable value,refers to an approximately +/−10% variation from a given value. It isunderstood that such a variation is always included in any given valueprovided herein, whether or not it is specifically referred to.

As used herein, the term “and/or” refers to and encompasses any and allpossible combinations of one or more of the associated listed items(e.g. one or the other, or both), as well as the lack of combinationswhen interrupted in the alternative (or).

As used herein, the term “accumulator” refers to equipment that formspart of a wellsite hydraulic system that is used for opening and closingvalves and blowout preventers of wellsite equipment. Accumulatorstypically have four components: a hydraulic pump, a hydraulic tank,accumulator bottles for storing hydraulic energy and valves forregulating the hydraulic equipment. An accumulator may also be referredto as a closing station or a closing unit. An accumulator may alsocontrol the position of a valve actuator of each of the frac tree valvesand/or the zipper manifold valves.

As used herein, the term “consultant” refers to a representative of anexploration-and-producing oil company who may be present at the well pador remote from the well pad and duly authorized to make proceduraldecisions about operations at the well pad or multiple well pads.

As used herein, the term “frac tree” refers to an assembly of valves,gauges and chokes that are part of a wellhead and used for thefracturing process. The frac tree can include multiple valves thatcontrol the flow of fluids through, to or from the well, to controlpressure between different sections of the wellhead.

As used herein, the term “wellhead” refers to the equipment andcomponents present at the surface end of a well that may include a fractree, a Christmas tree, a blowout preventer assembly, and that at leastpartially provides physical support to the well below the surface end.

As used herein, the term “wellhead technician” refers to an individualperson who actuates the valves on a wellsite, whether the valves arehydraulically, electronically, pneumatically or manually actuated,directly or indirectly.

As used herein, the term “well pad” refers to a physical location thatcomprises two or more wellsites and such wellsites are in proximity toeach other to facilitate the sharing of wellsite equipment, personneland/or other operational infrastructure for operations to be performedon such wellsites.

As used herein, the term “wellsite” refers to a physical location inproximity to one or more geological formations and where well operationsare occurring on an oil and/or gas well.

As used here, the term “zipper manifold” also referred to as a “fraczipper manifold” refers to a manifold that is used for conducting anddirecting high-pressure, hydraulic fracturing fluid from a source intoone or more wells on a well pad. Zipper manifolds can includehydraulically actuated or manually actuated valves that regulate thefluid flow within the manifold. Zipper manifold may also be usedinterchangeably with the terms “frac line” or “trunk line”.

The embodiments of the present disclosure will now be described and inreference to FIG. 1 through to FIG. 10 .

FIG. 1 shows a non-limiting example of an apparatus 10 that isconfigured to detect and indicate the operational position of a wellheadvalve 2000. The wellhead valve defines a central bore 2001 which thevalve body 2012 can move between a closed position (FIG. 1B) and an openposition (FIG. 1C). The valve body 2012 can move linearly between theclosed and open position under the influence of an actuator 2002, whichin FIG. 1 is a hydraulic actuator. When the valve body 2012 moves, avalve stem 2010 moves in the same fashion and direction so that a targetsurface 2011 of the valve stem 2010 will move towards and away from theapparatus. The valve stem is protected within a valve guard 2014, whichmay also be referred to as a valve shroud.

The apparatus 10 can be operatively coupled to a non-moving portion of avalve, a surface of wellsite equipment so that a sensor 50 of theapparatus 10 is in fluid communication and, therefore, acousticcommunication and/or visual communication and/or electromagneticcommunication with the target surface 2011 of the valve. As shown in thecomparison of FIG. 1B the apparatus 10 can be operatively coupled at oneend to the valve guard 2014. As shown in FIG. 1B, 1C, 1D, and 1E, theapparatus 10 is configured to operatively couple to valve guards 2014and 2014C (as but one example of a non-moving part of the valve) ofvarious shapes, dimensions and configurations without requiring effortto pre-measure the valve guard and then to manufacture a specificapparatus that meets the specific valve guard to which the apparatus 10is intended to be operatively coupled. Without being bound by anyparticular theory, the apparatus 10 is configured to be operativelycoupled to a non-moving part of the valve (which also refers to othernon-moving surfaces of the wellsite equipment) to accommodate outerdiameter (or similar external diameters for non-circular components)between 0.25-25 inches, 0.5-20 inches, 0.75-15 inches, 1-10 inches,1.5-7.5 inches, 2-5 inches and all ranges of sizes therebetween.

FIG. 2A shows another embodiment of the apparatus, referred to asapparatus 10B, which has all of the same components, features andfunctionality of apparatus 10 (described further below) with theexception that the apparatus 10B includes a fitted valve guard 12A aspart of the apparatus 10B. This fitted valve guard 12A can beoperatively coupled with and sealed against the other components of thevalve and/or wellsite equipment so as to prevent fluid and debrisintrusion that may interfere with the valve's movement.

FIG. 2B shows another embodiment of the apparatus, referred to asapparatus 10C, which has all of the same components, features andfunctionality of apparatus 10 (described further below) with theexception that the apparatus 10C is configured to be used with arotationally actuated (rather than linearly actuated) valve. Theapparatus 10C further comprises a housing 11 that can be positionedadjacent the rotary actuator 2006 (in this case a wheel handle). Theapparatus 10C also includes a target surface 2011 that can beoperatively coupled to the rotational actuator shaft 2016 (in this casethe threaded member upon which the rotatory actuator 2006 rotates). Inthis embodiment, as the rotatory actuator 2006 moves towards or awayfrom the apparatus 10C the target surface 2011 will move linearlytowards and away from the apparatus 10C but with minimal or no rotation,which allows the apparatus 10C to detect the position of a moving partof the valve in a contactless fashion.

Without being bound by any particular theory, the embodiments of thepresent disclosure allow for contactless (i.e. non-contact) detection ofthe position of a moving part of a valve. The benefits of contactlessdetection is that the apparatus 10 can be more compact (i.e. occupy asmaller physical space) and, therefore, more stable than currentlyavailable contact-based position sensors. This is an important featurewhen the embodiments of the present disclosure are deployed on awellsite because the compact physical footprint will mitigateinadvertent accidents caused by contacting other equipment that is beingmoved around the wellsite. Furthermore, the apparatus 1—can bepositioned in such a manner as to be closer to the valve, which mayprovide the benefit of a reduced cantilever as the apparatus extendsoutwardly from the valve. Furthermore, the contactless detection of theposition of the moving part of the valve provided by the embodiments ofthe present disclosure may also reduce the wear and tear of thecomponents of the present disclosure.

FIG. 3 shows the apparatus 10 as comprising 10 has a first end 12A andan opposite second end 14B. The first end 12A is configured to beoperatively coupled to a non-moving part of a valve (as shown in FIG. 1and FIG. 2 ). Some non-limiting examples of such non-moving parts of thevalve include a valve bonnet, a stem shroud, a valve body, a flange, ayoke and the like. Furthermore, for the purpose of this disclosure, theterm “non-moving part(s) of the valve” is also understood to includeother surfaces of the wellsite equipment of which the valve is afunctional component. Because the non-moving part of the valve can varybased on the type of well site equipment, type of valve, equipment/valvemanufacturer, equipment/valve model and the like, the first end 13A canbe of various dimensions to operatively couple the first end 12A of theapparatus 10 to the non-moving part of the valve. The adaptability ofthe first end 12A of the apparatus 10 to take various configurations anddimensions allows the apparatus 10 to be used on valves of differentshapes, dimensions and configurations.

In some embodiments of the present disclosure, the apparatus 10 includesa mount portion 12, which may also be referred to as a mount andmounting portion, and a housing portion 14. The mount 12 may define thefirst end 12A of the apparatus 10 and the housing portion 14 may definethe second end 14B of the apparatus 10.

In some embodiments of the present disclosure, the mount 12 may comprisea ring plate 13A that defines an inner aperture. The diameter of theinner aperture can be of such a dimension that it is able to bepositioned about a portion of the non-moving part of the valve. Thefirst end 12A may also include a coupling mechanism that removablycouples the first end 12A about the non-moving part. FIG. 3 shows thenon-limiting example of brace members 15 that are connected at one endto the ring plate 13A, extending away therefrom. The brace members 15each define one or more apertures for receiving a coupling member 16therethrough. FIG. 3A and FIG. 3B each show the non-limiting examples ofcoupling members 16 as being threaded members with a first end 16A thatcan be positioned to abut against a surface of the non-moving part andtightened thereagainst in order to removably couple the first end 12A tothe non-moving part of the valve. As will be appreciated by thoseskilled in the art, the dimensions and manner by which the mount 12 isoperatively coupled to the non-moving part can be varied and is notlimited by the examples provided in this disclosure. For example, themount 12 may completely encircle about a portion of the non-moving partof the valve or not. The removable coupling performed by the mount 12need only be strong enough so as to maintain the position of theapparatus 10 relative to the moving part of the valve for the time frameduring which it is desirable to know the operational position of thevalve while the apparatus 10 is exposed to the environment of thewellsite.

The housing portion 14 refers to a part of the apparatus 10 thatencloses and/or protects and/or couples to and/or otherwise retains asensor 50 in a given, fixed position relative to the non-moving part ofthe valve. The housing portion 14 is configured to receive the sensor 50therewithin. By “configured to receive” it is meant that the structureof the housing portion 14 allows for at least a portion of the sensor 50to be enclosed and/or protected and/or coupled to and/or otherwiseretained by the housing portion 14. For example, the housing portion 14may define an interior space 51 of suitable size and shape toaccommodate at least a portion of the sensor 14 (see FIG. 4 ).

The apparatus 10 may be monolithic or modular. For example, the mount 12and the housing portion 14 may be formed as a single monolithiccomponent or as separate modular portions that together form theapparatus 10. For example and as shown in the non-limiting embodimentillustrated in FIG. 3 , the mount 12 and the housing portion 14 may beseparate and distinct pieces that can be removably coupled together.Non-limiting examples of this modular form of the apparatus 10, themount 12 and the housing portion 14 may be coupled together by a flangedconnection made up a second ring plate 13B of the mount 12 andcorresponding flange plate 18 that forms part of the housing portion 14.The second ring plate 13B and the flange plate 18 are removably coupledtogether by one or more securing members such as screws, pins, shanks,bolts or combinations thereof. Without being bound by any particulartheory, when the mount 12 and the housing portion 14 are modular, thatcan allow an user of the apparatus the ease of having different mounts12 of various dimensions and configurations available to best ensurethat the apparatus 10 can be removably coupled to the non-moving part ofthe valve in a desired fashion.

The apparatus 10 may be of any material suitable for withstanding thewellsite environment. In some embodiments, portions of the apparatus 10is made of metal or a metallic alloy such as steel, includingconventional steel or high-tensile steel. In some embodiments of thepresent disclosure, portions of the apparatus 10 are made of plastic, apolymer or a polymer blend. The mount 12 and the housing portion 14 canbe made of the same material or not.

The housing portion 14 is configured to receive the sensor 50. Thehousing portion 14 may receive the sensor 50 entirely therewithin, ornot. In some embodiments of the present disclosure, the sensor 50 isremovably couplabled to the housing portion 14.

The sensor 50 is configured to detect the position of a moving part ofthe valve and to provide an output signal that indicates the operationalposition of the valve relative to a fixed reference point. Examples ofsensors 50 that are suitable for use in the apparatus, system, andmethods of the present disclosure include any type of sensor that candetect the distance between the sensor 50 and a target surface, which ispreferably a surface of the moving part of the valve, but may also be anon-moving surface of the valve if the sensor 50 is operatively coupledto the moving part of the valve. A non-limiting example of such a sensoris a time of flight (TOF) sensor. In some embodiments of the presentdisclosure, the TOF sensor may be an ultrasonic TOF sensor assembly thatcomprises an ultrasonic sound source, an ultrasonic sound detector and aprocessor. While known in the art, such an ultrasonic (TOF) sensoroperates by the sound source emitting ultrasonic soundwaves at a targetwhich reflects the soundwaves. The reflected soundwaves are detected bythe ultrasonic sound detector. The microprocessor compares the timedifferential between when the emitted soundwaves are emitted and whenthe received soundwaves are received to determine the distance betweenthe emitter and the target. The microprocessor then converts this timedifferential into a time differential output signal that is thencommunicated externally to the apparatus 10 as either a voltage signalor a current signal. The microprocessor may also compensate for otherfactors such as noise and temperature to improve the accuracy of thedistance calculations.

As will be appreciated by those skilled in the art, TOF sensors otherthan ultrasonic TOF sensors are also contemplated herein, such as laserTOF sensor assembly, LIDAR TOF sensor assembly, a radar TOF sensorassembly or combinations thereof. As will be appreciated by thoseskilled in the art, other types of sensors are also contemplated herein,such as a string pot sensor assembly, a rotary potentiometer/rotaryencoder, a linear variable differential transformer (LVDT) sensorassembly, a limit switch assembly, a magnetic pick-up sensor assembly orcombinations thereof.

As shown in the non-limiting illustration of FIG. 3 , the housingportion 14 may also define the inner surface of an optional focusingtube 54. The focusing tube 54 may comprise at least a portion of whichthat has a conical cross-sectional shape. As shown in FIG. 32 , thefirst end of the focusing tube 54 that is proximal the mount 12 may havea smaller cross-sectional area than the opposite, second end of thefocusing tube 54 that is proximal the sensor 50. Without being bound byany particular theory, the conical cross-sectional shape of the focusingtube 54 may focus the soundwaves within the focusing tube travelling inone direction and filter soundwaves in the other direction, which mayenabling the sensor 50 to determine the position of the target through asmaller aperture than other designs allow for. In some embodiments ofthe present disclosure, the inner surface of the housing portion 14 canbe shaped, for example by machining or otherwise, to define thecross-sectional shape of the focusing tube 54. Alternatively, an insertbody may be fixed within the housing portion 14 and the insert body willinclude an inner surface that defines the cross-sectional shape of thefocusing tube 54.

In some embodiments of the present disclosure, the housing portion 14may be monolithic or modular. As shown in the non-limiting illustrationof FIG. 4 , the housing portion 14 can comprise three separate modularcomponents, namely a first end component 32, a second end component 30and an intermediate component 31.

The first end component 32 may include the flange plate 18 and beremoveably couplable to the mount 12 as described herein above.

The second end component 30 may define an inner plenum 51 in which atleast a portion of the sensor 50 is received and through whichelectronic cables (not shown) can extend from the sensor 50 out througha cable extension 24 via a cable conduit 26 to terminate in a cableconnector 28. The electronic cables are configured to conduct electronicsignals, electronic power or both to and from the sensor 50. The cableconnector 28 can be a multi-pin connector that is configured tooperatively connect the electronic cables within the plenum 51 toprovide external power and/or communication channels. In someembodiments of the present disclosure, the sensor 50 may be powered by abattery and the sensor 50 may be configured to wirelessly communicatethe output signal generated by the microprocessor and to receivewireless commands from a user.

The intermediate component 31 can be removably connected to the secondend component 30 by flanges 34 and 36 and connection members that extendtherethrough. The intermediate component 31 may also include a fixingbody 56 that is configured to protect the sensitive electroniccomponents of the sensor 50, to maintain the orientation of the sensor50 within the housing portion 14 and, optionally, to define a portion ofthe focusing tube 54. In some embodiments of the present disclosure, thefixing body 56 also reduce external interference, such as noise andthermal fluctuations, with the operation of the sensor 50. Theintermediate component 31 may also removably connect with the first endcomponent 32. In some embodiments of the present disclosure, a quickrelease connection may be used to removably connect the intermediatecomponent 31 and the first end component 32. The quick releaseconnection may include a biased clamp member 20 and a retention member22. The biased clamp member 20 can include a biasing member that forcestwo opposing handles away from each other, which in turn creates aninward compression force that acts upon a portion of the intermediatecomponent 32 and the first end component 32. The retention member 22 canbe used to lock the biased clamp member 20 in a desired position, so asto maintain the clamping force. In order to release the clamping force,the retention member 22 can be loosened and the two handles of thebiased clamping member 20 can be moved towards each other to reduce orrelieve the clamping force. As will be appreciated by those skilled inthe art, other types of quick release connections are also contemplatedby the present disclosure. Without being bound by any particular theory,the embodiments of the present disclosure that include the quick releaseconnection may provide an operator access to maintain and/or replace thesensor 50 without having to decouple the mounting 12 from the non-movingpart of the valve and without having to decouple the first end component32 from the mount 12.

FIG. 5 shows another embodiment of the present disclosure that relatesto an apparatus 10A that has the same components as describedhereinabove regarding the apparatus 10 with the addition of a push rodassembly 100. The push rod assembly 100 is configured to be operativelycoupled to the moving part of the valve, such that when the moving partof the valve moves to change the operational position of the valve, thepush rod assembly 100 will also move and that movement can be detectedby the sensor 50.

The push rod assembly 100 comprises an assembly housing 101 that isremovably couplable at one end to the second ring plate 13B by a flange118A and to the flange plate 18 of the first end component 32 by aflange 118B. The push rod assembly 10 also comprises a rod 102 and apiston cap 104 is connected to one end of the rod 102. The rod 102 andthe piston cap 104 are both positioned within the assembly housing 101.The rod 102 can be inserted into a valve shroud of the valve and forcedagainst the moving part of the valve, such as the valve stem, via abiasing member 106 that creates a biasing force that pushes the rod 102towards the valve stem (as shown by the arrow X in FIG. 5B). In otherembodiments of the present disclosure, the rod 102 is connected to themoving part of the valve by adhesive, one or more magnets, a mechanicalattachment or combinations thereof, such that when the moving part ofthe valve moves, thus changing the operational position of the valve,the rod 102 will move similarly. Movement of the rod 102 will cause thepiston cap 104 to also move and the change in position of the piston cap104 will change the time of flight analysis conducted by themicroprocessor of the sensor 50. While the focusing tube 54A is shown asnot having a conical cross-sectional shape in FIG. 5B, the skilledperson will appreciate that such a shape is still contemplated by thisdisclosure.

Without being bound by any particular theories, the push rod assembly100 enables the sensor 50 to read the operational position of a valvethat has a small aperture and/or that that otherwise would not besuitable for position detection by the sensor 50. Without being bound byany particular theory, the push rod assembly 100 translates movement ofthe moving part of the valve, such as but not limited to the valve stem,to movement of the piston cap 104 and the piston cap 104 provides alarger target surface against which the sensor 50 can emit and receiveultrasonic sound waves. The push rod assembly 100 also isolates thesensor 50 and the sensor read path (i.e. between the emitter and thetarget) from environmental issues such as water, grease, debris and iceby enclosing the rod 102 and the piston cap 104 inside the assemblyhousing 101.

In operation, the two apparatus 10, 10A work in a similar fashion. Thesensor 50 emits ultrasonic sound waves that travel in a first direction(shown as arrow X in FIG. 4 and FIG. 5 ). The sound waves travel alongthe sensor read path through the focusing tube 54, 54A and reflect offthe target surface. In the case of apparatus 10, the target surface is asurface of the moving part of the valve, such as but not limited to thevalve stem. In the case of apparatus 10A, the target surface is thepiston cap 104. The reflected sound waves then travel in a secondopposite direction (shown as arrow Y in FIG. 3 and FIG. 4 ) along thesensor read path through the focusing tube 54, 54A to strike a receivingend 52 of the sensor 50. From there, the microprocessor generates thetime differential output signal, as described above, and electronicallycommunicates that externally.

As will be appreciated by those skilled in the art, the detectedposition of the moving part of the valve is indicative of theoperational position of the valve. For example, a valve whoseoperational position controls the flow of fluids towards, through oraway from a piece of wellsite equipment. The output signal generated bythe sensor 50 may indicate that the valve is in a first operationalposition and, therefore, it is indicated that the valve is in an openposition. When the output signal indicates the actuator is in a secondoperational position, the output signal will indicate that the valve isin a closed position. Actuating the valve between an open position and aclosed position regulate the flow of fluids through the valve, which inturn regulates the flow of fluids towards, through or away from theassociated wellsite equipment. In some embodiments, the output signalmay indicate that the valve is in an intermediate operational positionbetween the first position and the second position and, therefore, thisindicates that the valve is in a partially open position and fluid flowthrough the valve may be partially restricted as compared to when thevalve is in an open position.

Some embodiments of the present disclosure provide a system 1000 fordetecting and indicating an operational position of a valve of wellsiteequipment (see FIG. 6 ). The system 1000 comprises one or more ofapparatus 10 or 10A that are each configured to detecting the positionof the moving part of the valve and providing an output signal thatindicates the operational position of the valve and a processor 400 forreceiving and processing the output signal into a processed outputsignal.

As used herein, the term “processor” is intended to refer to a computingunit that executes a program. In some embodiments of the presentdisclosure, the program executed converts the output signal from the atleast one sensor into a processed output signal. The processor 400 maybe one or more single-core or multiple-core computing processors such asINTEL® microprocessors (INTEL is a registered trademark of Intel Corp.,Santa Clara, Calif., USA), AMD® microprocessors (AMD is a registeredtrademark of Advanced Micro Devices Inc., Sunnyvale, Calif., USA), ARM®microprocessors (ARM is a registered trademark of Arm Ltd., Cambridge,UK) manufactured by a variety of manufactures such as Qualcomm of SanDiego, Calif., USA, under the ARM® architecture, or the like. For thepurposes of this disclosure, the term “processor” may be used to referto multiple processors that are operatively connected to each other, forexample, as sub-processors of a master processor.

In some embodiments of the present disclosure, the system 1000 actuatorfurther comprises one or more remote display units 500 for receiving theprocessed signal and displaying an image indicative of the operationalposition of the one or more valves that each have an associatedapparatus 10 or 10A. By “remote display unit” it is meant that thedisplay unit need not be positioned at the well. For example, the remotedisplay unit may be in a service truck, a trailer or a control center atthe well site or at a control center that is at a remote locationdistant from the well site. The remote display unit 500 may comprise oneor more display modules for displaying images, such as monitors, LCDdisplays, LED displays, projectors, and the like. The remote displayunit 500 may be a physically integrated part of the processor 400 and/orthe user interfaces (for example, the display of a laptop computer ortablet), or may be a display device physically separate from, butfunctionally coupled to, other components of the processor and/or theuser interfaces (for example, the monitor of a desktop computer). In anembodiment, the remote display unit 500 may be a Human-Machine-Interface(HMI). At least one advantage of the remote display unit 500 is areduction of transport of individuals to wellsite locations. Anotheradvantage of a remote display unit 500 is that the operational positionof multiple valves on multiple wellsites/well pads can be monitored bymultiple users both at the wellsite/well pad and/or at a centralizedcontrol center. As will be appreciated by the skilled person, the arrowsdepicted in FIG. 6 represent electronic communication, wired, wirelessof both, between the different components of the system 1000.

In some embodiments of the present disclosure, the system 1000 describedherein may be integrated into an existing control system at a wellsiteand/or at a remote location.

The program that is executable by the processor 400 can be used to mapand calibrate the output signal of sensor 50 of each apparatus 10 or 10Ato a respective operational position. For example, processor 400 cancreate a well identification number and a valve identification numberfor each well and valve that will be operatively connected to the system1000. Next the operator can actuate the valve into a first operationalposition and then instruct the processor 400, optionally via a HMIfunctionality of the remote display unit 500) to add the output signalof the sensor 50 to indicate a first operational position, this isreferred to as a first calibration step. The processor 400 will alsoassign a created well valve identification number to the valveassociated with the sensor 50 that provides an altered output signal (asbetween prior to actuating the valve and after actuating the valve).When all valves have been associated a valve identification number, eachvalve will be mapped within the system 1000 and each valveidentification number may then be displayed on the remote display unit500 in such a manner that the user will be able to discern theoperational position of all valves that are assigned a valveidentification number. The operator may also perform the firstcalibration step multiple times for each valve and the program willcalculate an average to assist in more precisely calibrating the outputsignal for the first operational position, this may be referred to as afurther first calibration step. Next the operator can actuate the valveinto the second operational position and then instruct the processor 400to add the output signal of the sensor 50 as indicating the secondoperational position, this may be referred to as a second calibrationstep. The calibration of the sensor 50 output signal to indicate thatthe valve is in the second operational position can also be averagedover multiple adding steps by performing further second calibrationsteps.

If desired, depending on the specific valve function, the operator mayalso actuate the valve to one or more intermediate operational positionsand instruct the program to add the output signal of the sensor 50 asindicating as one or more intermediate operational positions of valve.Alternatively or additionally, the program can be instructed that anyoutput signal of the sensor 50 that is between the measure of the firstoperational position and the second operational signal will indicate anintermediate position.

Preferably, each sensor 50 must be calibrated to the valve it isinstalled on in order to provide an accurate indication of theoperational position of the valve. The calibration process takes ameasurement of the sensor 50 output signals in the first operationalposition, the second operational position or therebetween.

Optionally, the user can also use the processor 400 to apply anacceptable variance range, also referred to as a dead band, within theoutput signal to filter any signal noise within the sensor 50 outputsignal and to allow for any physical inconsistency or errors in physicalpositioning of the valve. For example, after following the steps aboveand establishing that an output signal of X (volts or current) indicatesthat the valve is in the first operational position and an output signalof Y (volts or current) indicates that the valve is in the secondoperational position, the processor can calculate the difference betweenX and Y to establish a range between the two output signals and appliesa scale of 0-100 of the calculated range. The user can then instruct theprocessor 400 calculate a desired percentage of the established scale sothat a signal within Z1% (on either side) of X will be indicative of thevalve being in the first operational position and that a signal withinZ2% of Y will be indicative of the valve being in the second operationalposition. Z1 need not equal Z2. The applied scale will also indicate tothe user the relative percentage that a valve is open or closed, whichmay also be calculated (based upon inputting applicable dimensionalmeasurements into the processor 400) to determine an actual distancethat a valve is in an open operational position or a closed operationalposition.

FIG. 7 shows a further embodiment of a system 1000A that has the samecomponents as system 1000, with the further components of: the processor400 includes a digitizer 402, a microprocessor 404 and a calibrationmodule 406. The digitizer is configured to convert the output signalfrom a voltage signal or a current signal to a digital signal. Themicroprocessor 404 is configured to process the digital signal accordingto the instructions provided by the program and the user. Thecalibration module 406 is configured to perform and calculate thecalibration method described above. The system 1000A may furthercomprise a database module 1002 for storing all processed signal datareceived by the processor 400 and for delivering to such stored data toa remote database infrastructure 1010, such as a cloud-based or serverbased database. Optionally, the user may access the stored data directlyfrom the remote database infrastructure 1010, via HMI features of theremote display unit 500, or indirectly through the database module 1002.

In some embodiments of the present disclosure, the system 1000A may alsocomprise a remote valve control (RVC) system 2000 that includes a dataprocessor module 2002, an automation controller 2004, a remote valveactuator (RVA) controller 2006 and one or more RVA actuators 2008 n (onefor each valve that is being remotely controlled by the system 2000).The data processor module 2002 is configured to receive the data withinthe processed signal output from the processor 400 and to furtherprocess that data, which reflects the position that a given valve is in.The data processor module 2002 may then determine whether or not it isappropriate to change the operational position of the valve, asdescribed further below. In event that the data processor module 2002determines that the operational position of the valve can be changed,the data processor module 2002 may send a change position command to anautomation controller 2004, which is configured to translate and directa change operational position command to a hardware controller 2006,which in turn can cause the actuator 2008 n to move the actuator of thevalve and change the operational position of the valve, with or withouta user's further intervention. In the event that the data processormodule 2002 determines that the operational position of the valve shouldnot be changed, then it can send no further commands or it can send amaintain position command to the actuator 2008 n, via the automationcontroller 2004 and the hardware controller 2006.

Once each apparatus 10/10A is mapped to its associated valve, eachactuator 2008 n can also be mapped to the same valve. So that a user canuse the system 1000A to receive an indication as to the operationalposition of a given valve and then directly actuate that valve to changeits operational position. For example, each actuator 2008 n isconfigured to be controlled by receiving commands remotely by a user,directly by a user or in an automated fashion under control of acontroller, microcontroller, a processor or microprocessor (as describedabove). The actuator 2008 n is further configured to move the actuatorso as to move a valve between the first operational position, the secondoperational position and the intermediate operational position betweenthe first and second positions.

Each actuator 2008 n comprises a motor that can be electrically powered,pneumatically powered or hydraulically powered. Each type of motor hasits own advantages and may be selected according to its particularapplication. For example, electrically powered motors are easilyreprogrammable, environmentally friendly, and can be precisely andflexibly controlled. Suitable and non-limiting examples of suchelectrically powered motors can include direct current (DC) motors,synchronous and asynchronous motors, alternating current (AC) motors,stepper motors, and servomotors. Pneumatically powered motors are simpleto use, they are durable, can provide a high-force output, and they canbe used in hazardous environments. Suitable examples of pneumaticallypowered motors include rack and pinion actuators and rotary vaneactuators. A non-limiting example of a pneumatic rotary vane actuator isa Model 07 Actuator, commercially available from Kinetrol™ LTD.Hydraulic rotary actuators can be used for applications that requiringhigh torque in order to move the actuator of a given valve. Commondesign configurations for such hydraulically powered motors includepiston type, vane type, or gear type.

In some embodiments of the present disclosure, the actuator 2008 n maycomprise another mechanism than the motor for moving the actuator of thevalve, such as a linear actuator or another type of rotary actuator. Thelinear actuator and the rotary actuator can be electrically powered,pneumatically powered or hydraulically powered.

FIG. 8 provides logic flow diagrams that illustrate how the system 1000Acan operate a method to remotely control and monitor the operationalposition of one or more valves on a wellsite/well pad. FIG. 8Arepresents a scenario where the sensor 50 (shown as VPS1) has detectedthe position of a moving part of the valve and is indicating thatposition be sending the output signal data to the processor 400 (shownas logic control). Within the processor 400, a determination is madewhether or not the specific valve should maintain its currentoperational position (i.e. status) or whether or not it is safe toproceed to a next step of changing the operational position of thevalve. The determination of whether or not it is safe to proceed isbased upon a full mapping of all applicable valves on the well site/wellpad being stored within the processor 400 and further data inputs intothe processor 400 that will allow a user to understand what step of aparticular service is being performed at the time. For example, thefurther data inputs may indicate that there is currently a high pressureflow of fracturing fluids being directed into the well. As such, that isnot a safe time to change the operational position of a master valvefrom open to closed. This is but one example of how the valve positioninformation provided by the apparatus 10/10A can be integrated into adata capture and storage system that allows users to receive visualindications, for example on the HMI of the remote display unit 500, andto make decisions—based on the step of a well service operation that isoccurring—as to whether or not to change the operational position of oneor more valves. The skilled person will appreciate that various forms offurther data inputs can be integrated to alert the user as to the stepof a particular service that is being performed at a given time. Suchintegrated systems are described in the Applicant's prior filed patentapplication (PCT/CA2019/050890 entitled APPARATUS, SYSTEM AND PROCESSFOR REGULATING A CONTROL MECHANISM OF A WELL), the entire disclosure ofwhich is incorporated herein by reference.

FIG. 8B represents a scenario where the sensor 50 (shown as VPS1) hasdetected the position of a moving part of the valve and is indicatingthat position be sending the output signal data to the processor 400(shown as Logic Control) where a valve position lockout is present oneach valve. The valve position lockout is configured to prevent movementof a locked out valve from its current operational position. When alockout is unlocked, the operational position of the valve can bechanged. The lockout mechanism can be a physical barrier that restrictsphysical interaction or movement with a valve's actuator or the lockoutmechanism can be a systematic barrier that prevents the flow of power(hydraulic, pneumatic or electrical) to a mechanically controlled valveactuator. In other embodiments of the present disclosure, the lockoutmechanism can be a digital lockout, whereby the flow of electrical,pneumatic and hydraulic power for performing an operation on a well iscontrollable by a digital control system of which the processors 400 cancontrol one or more aspects of. Non-limiting examples of such digitalcontrol system are described in Applicant's prior filed patentapplication (PCT/CA2019/050890 entitled APPARATUS, SYSTEM AND PROCESSFOR REGULATING A CONTROL MECHANISM OF A WELL). In the event that thesensor 50 indicates that the valve is not in a desired operationalposition for a step of the operation that is being performed on the wellor soon to be performed on the well, the processor 400 can proceed tounlock the lockout on the valve and this will result in a further signalbeing communicated to the processor 400, which will then assess whetheror not the unlocked status is acceptable or not. If acceptable, the usermay then proceed to the next step of the process. If the unlocked statusis not acceptable, then the lockout may be re-locked to prevent anychange in the operational position of the valve.

FIG. 8C represents a scenario where it is desired to move the valve toan intermediate position so that the apparatus 10/10A indicates that thevalve is approximately halfway between the 0 and 100 of the appliedscale (as discussed above).

FIG. 9 shows a scenario where the system 1000A where each valve that isincluded has its own apparatus 10/10A (shown as VPS1) and its ownactuator 2008 (shown as RVA).

In some embodiments, the present disclosure provides a method 2000 fordetecting and indicating an operational position of valve of wellsiteequipment. The method 2000 comprises a step 2100 of releasably couplingan apparatus 10/10A to a non-moving part of the valve or wellsiteequipment. The method 2000 also comprises a step of detecting 2200 theposition of a moving part of the valve, relative to a fixed point (orotherwise), a step 2202 of indicating the detected position of themoving part of the valve by communicating an output signal. Optionally,the method comprises a step 2204 of observing the output signal so thatoperators of one or more services being performed at a given well canmake operational decisions.

The step 2200 of detecting a position of the actuator may be performedby the sensor 50. The sensor 50 may be in fluid communication and,therefore acoustic communication with a moving part of the valve.Alternatively, the sensor 50 may be coupled to the moving part of thevalve and in fluid communication with a non-moving part of the valve(which acts as the target surface).

In some embodiments of the present disclosure, the step 2202 ofindicating comprises: a step 2210 of processing the output signal into aprocessed output signal; and a step 2220 of converting the processedoutput signal and transmitting the processed output signal, via wired orwireless electronic communication, for display on a display unit, thatmay be remote from the valve itself, or not. In an embodiment, theprocessing step is by a processor such as the processor 400 describedelsewhere herein. In an embodiment, the display unit may be the remotedisplay unit 500 described elsewhere herein. In an embodiment, the imageis a graphical image, an alphanumeric image, a colour, or anycombination thereof. In an embodiment, a change of the graphical image,such as for example a colour change, may indicate whether the actuatoris in a first position, a second position or therebetween. Furthermore,the data that is used to generate the image can be used in numericalform for further control or analysis work.

In an embodiment, the processed output signal (and the associated imagedisplayed on a remote display unit) indicates the position of a movingpart of the valve. The position of the moving part of the valveindicates the operational position of the valve being an open position,a closed position, or, optionally, an intermediate position.

The image on the display unit may inform a consultant or other user tomake operational decisions about service operations being performed atthe well pad for example, for example whether or not to actuate one ormore valves of wellsite equipment, turn on or off one or more fluidpumps, extend or retract wireline or coiled tubing from the well, orother operational decisions that are apparent to those skilled in theart.

What is claimed is:
 1. An apparatus for detecting a target surface of avalve and indicating an operational position of a valve, the apparatuscomprising: a. a mounting portion configured to removably couple to anon-moving part of a valve or a non-moving part of an associatedequipment; b. a housing portion; c. a sensor at least partially housedin the housing portion, the sensor configured to be in communicationwith the target surface for contactless detecting of the operationalposition of the valve within a specified range of movement based upon adetected distance between the sensor and the target surface, wherein thetarget surface moves linearly towards and away from the sensor, andwherein the sensor comprises an ultrasonic TOF sensor assembly, a laserTOF sensor assembly, a LI DAR TOF sensor assembly, a radar TOF sensorassembly or combinations thereof; and d. a push rod assembly positionedbetween the sensor and the target surface.
 2. The apparatus of claim 1,wherein the target surface is defined by a moving part of the valve. 3.The apparatus of claim 1, wherein the sensor is in acousticcommunication with the target surface.
 4. The apparatus of claim 1,wherein the sensor is in electromagnetic communication with the targetsurface.
 5. The apparatus of claim 2, wherein the moving part of thevalve moves in a linear fashion.
 6. The apparatus of claim 2, whereinthe moving part of the valve is actuated by a rotatable actuator and thehousing houses the target surface and the target surface is fixable to apart of the rotatable actuator.
 7. The apparatus of claim 1, wherein aninner surface of the apparatus defines a focusing tube.
 8. The apparatusof claim 1, wherein the sensor comprises an ultrasonic TOF sensorassembly.
 9. The apparatus of claim 1, wherein the mounting portioncomprises an adaptable mount.
 10. The apparatus of claim 1, wherein themounting portion comprises a valve guard that is sealingly and removablyconnectible to the valve or associated equipment.
 11. A system fordetecting a target surface of a valve and indicating an operationalposition of the valve, the system comprising: a. an apparatuscomprising: i. a mounting portion that configured to removably couple toa non-moving part of a valve or a non-moving part of an associatedequipment; ii. a housing portion; iii. a sensor at least partiallyhoused in the housing portion, the sensor configured to be incommunication with the target surface for contactless detecting of theoperational position of the valve within a specified range of movementbased upon the detected distance between the sensor and the targetsurface, wherein the target surface moves linearly towards and away fromthe sensor, and the sensor further configured to indicate theoperational position by communicating an output signal and wherein thesensor comprises an ultrasonic TOF sensor assembly, a laser TOF sensorassembly, a LIDAR TOF sensor assembly, a radar TOF sensor assembly orcombinations thereof; and iv. a push rod assembly positioned between thesensor and the target surface, and b. a processor that is configured toreceive the output signal and to generate a display signal thatindicates the operational position of the valve.
 12. The system of claim11, further comprising a display unit for receiving the processed signaland displaying an image that indicates the position of the actuator. 13.The system of claim 11, wherein the display unit is remote from thevalve or associated equipment.
 14. The system of claim 11, wherein thesensor comprises an ultrasonic TOF sensor assembly.
 15. A method fordetecting and indicating an operational position of a valve, the methodcomprising: a. removably securing an apparatus to a non-moving part of avalve or a non-moving part of an associated equipment, the apparatuscomprising a sensor, the sensor comprising an ultrasonic TOF sensorassembly, a laser TOF sensor assembly, a LI DAR TOF sensor assembly, aradar TOF sensor assembly or combinations thereof, b. contactlesslydetecting the distance between the sensor and a target surface of thevalve or associated equipment within a specified range of movement,wherein the target surface is operatively coupled to a moving part ofthe valve with a push rod assembly and moves linearly towards and awayfrom the sensor; and c. indicating the operational position of the valveactuator based on the detected distance.
 16. The method of claim 15,wherein the step of indicating comprises: a. a step of processing theoutput signal into a processed output signal; b. a step of convertingthe processed output signal to an image or data; and c. displaying theimage or data on a display unit.
 17. The apparatus of claim 1, whereinthe non-moving part comprises a valve bonnet, a stem shroud, a valvebody, a flange or a yoke.
 18. The system of claim 11, wherein thenon-moving part comprises a valve bonnet, a stem shroud, a valve body, aflange or a yoke.